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Read the WELCOME ALL BMWFANATICS post.
Crash's Jezebel in for a Rebuild-Rebuilding an e46 S54 UPDATE on page 26
- Thread starter Peter@AEW
- Start date
Crash_Nemesis
///Member
a1exander said:
Lets hope so... I was getting high as faaaak on fumes last week everytime I drove her. Ha ha ha.
:high: :dizzy:
well the previous location next to the ECU case was far from ideal... that compartment is right next to the intake for the AC also it would have gotten VERY dirty in there
Fordkoppie
///Member
a1exander said:Just a small update.
Car was delivered yesterday afternoon.
So this is how another professional works??:fencelook:
So much so, that it cant even get to you on its own
We had to take the oil filter housing to the engineers to get it welded so still waiting for it to come back so that we may proceed.
Have made the injector rail brackets as it needs to be raised by roughly 10mm to accommodate the new injectors known as Green Giants a name given to them by I suspect our Yankee brethren.
I am hoping to start it by Friday however the old saying of "the best laid plans of mice and men " may well apply.
Pics as soon as we start assembly.......
Have made the injector rail brackets as it needs to be raised by roughly 10mm to accommodate the new injectors known as Green Giants a name given to them by I suspect our Yankee brethren.
I am hoping to start it by Friday however the old saying of "the best laid plans of mice and men " may well apply.
Pics as soon as we start assembly.......
Today lined up the correct angles on the injectors as well as the vacuum rail and made 2 new sets of brackets to get everything to line up correctly.
Due to the fact that the new injectors are roughly 10mm longer the angle at which the fuel hard line as well as the injectors fit into the fuel rail is off 90 degrees.
To cut a long story short everything is at 90 degrees and there should be none of the leaks that were previously experienced or would have manifested over time as the rubbers on the injectors became more compressed with age.
In summary I am quietly optimistic that there will be no fuel leaks or vacuum leaks.
Reason that oil filter housing had to go in for welding
HAd to strip the engine harness and throttle actuator motor which was held on by 3 short bolts which are not the bolts I had initially installed.
Had it been left like that the actuator would have vibrated loose and dropped off.
Got 3 new ones from the agents and all is well.
Tomorrow is another day.........
Check fuel pressure
Re install original vacuum line to fuel filter
Connect original fuel hose
Cut new lengths of pipe for the manifold
Make up pipes for the ICV
Install charger bracket
More pics later
Last pic
Due to the fact that the new injectors are roughly 10mm longer the angle at which the fuel hard line as well as the injectors fit into the fuel rail is off 90 degrees.
To cut a long story short everything is at 90 degrees and there should be none of the leaks that were previously experienced or would have manifested over time as the rubbers on the injectors became more compressed with age.
In summary I am quietly optimistic that there will be no fuel leaks or vacuum leaks.
Reason that oil filter housing had to go in for welding
HAd to strip the engine harness and throttle actuator motor which was held on by 3 short bolts which are not the bolts I had initially installed.
Had it been left like that the actuator would have vibrated loose and dropped off.
Got 3 new ones from the agents and all is well.
Tomorrow is another day.........
Check fuel pressure
Re install original vacuum line to fuel filter
Connect original fuel hose
Cut new lengths of pipe for the manifold
Make up pipes for the ICV
Install charger bracket
More pics later
Last pic
are you altering the bracket or getting a new one made?
New hoses were cut to length
The correct plug for teh air sensor was acquired and spliced with solder and heat shrink. This is a trial fit and when finalised it will be covered in a similar sheath to that used by BMW.
Manifold being installed.
Chris was here a bit earlier and we started the car without the SC connected to the inlet manifold.
Car keeps fuel in the fuel rail and does not spray it all over the place as was previously the case.
Monday we will connect the SC hose to the inlet as well as a new air filter and hopefully we will have AFRs done on Tuesday.
The correct plug for teh air sensor was acquired and spliced with solder and heat shrink. This is a trial fit and when finalised it will be covered in a similar sheath to that used by BMW.
Manifold being installed.
Chris was here a bit earlier and we started the car without the SC connected to the inlet manifold.
Car keeps fuel in the fuel rail and does not spray it all over the place as was previously the case.
Monday we will connect the SC hose to the inlet as well as a new air filter and hopefully we will have AFRs done on Tuesday.
Went passed to see jezebel today, and all i can say is that peter is a mechanical genuis..
Chris and i did rush the build somewhat and even though the car was running, peters immaculate attention to detail meant that he would redo everything!
Peter and i went through the build and he pointed out some mistakes.
Taking on a custom build like this required the years of experience and knowledge that peter has and applied to all his work.
To cut a long story short, we all live and learn, and i am grateful to peter for his advice.
Just to update, i should have the car later this week to do logs, afr and prepare the new map.
Chris and i did rush the build somewhat and even though the car was running, peters immaculate attention to detail meant that he would redo everything!
Peter and i went through the build and he pointed out some mistakes.
Taking on a custom build like this required the years of experience and knowledge that peter has and applied to all his work.
To cut a long story short, we all live and learn, and i am grateful to peter for his advice.
Just to update, i should have the car later this week to do logs, afr and prepare the new map.
Crash_Nemesis
///Member
Burg, let me quote something Peter taught me over the last year I have spent watching him work on my and many other cars.
"The wise man is only wise because of the many fuck ups he made in his past."
You can only learn, and grow, from making mistakes. No one is perfect. And the best thing about this build, you and I learn't a lot from it.
You understand the complexity of the build, and the fact that this supercharger build is almost completely custom, only shows that this was not as easy as slapping a charger in and calling it a day, as we soon discovered.
Let me clear this up for everyone on the forum, this kit needed a lot of fabrication. It was not a simple bolt on kit that you can buy from VF or AA or ESS etc. Yes, it was originally a VF engineering kit, but I wanted a Blow off Valve and Alpha N software, which VF do not do (also, VF's tuning is apparently left much to be desired and many VF members have since moved over to an evolve Alpha N tune). That mean't we needed to change the intake manifold, the MAF sensor needed to be replaced with a air temp sensor, which needed to be relocated into the intake manifold and upstream from the supercharger, as opposed to being before the supercharger. The recirculation valve needed to be blocked off from the supercharger intake, an idler pulley needed to be fabricated, the sump oil return line needed to be blocked off, new vacuum lines needed to run from the emissions rail to the blow off valve, a new idle control pipe needed to be fabricated, an oil catch can needed to be installed with a line running from the tappet cover to the oil catch can and the brake booster needed to be re-installed into the supercharger intake pipe. Also, the injectors used are 10mm taller than OEM. So a new injector rail bracket needed to be made as well as fuel line extender needed to be used. None of these fabrications are done by VF. Active Autowerke does most of these mods to their kit, so we picked some ideas from some of the guys running those kits, but I am pretty certain this is one of the first, if not the first, Active Autowerke / VF engineering Hybrid supercharger kit. The idea behind this build was to take the best of both kits and make it work. The super efficient and large V3 supercharger from the VF kit mixed with the design of Active Autowerke intake to work the Alpha N tune file provided by Project Shift.
None of the above mentioned things that were fabricated came with the kit. Burg did his best to make things work, and whilst most of these things were temporary, in the end, the build just needed Peter's attention to detail to give it that one last touch of perfection.
I take my hat off to Peter and Burg for meeting up and going over the fixes Peter made to the build. As much as Peter swore from under the car, I could see today that he was happy to show Burg the small details that were required to give it that lasting touch of awesomeness.
So... the car is supercharged. The fuel rail is secured and new injectors are in. Peter should have the intake pipes installed today, and tomorrow the car can go for AFR's and logging so a custom tune file can be made for her.
As I mentioned, this kit is completely custom, so I have no idea what will happen after we do AFR's. The charger has been sitting for 2 years now, I just hope the bearings inside are ok. The worst thing that could happen now is that the supercharger is kaput and we went through all of this for nothing.
LOL. ok, enough negativity. Till the next update...
Jezebel returns.
"The wise man is only wise because of the many fuck ups he made in his past."
You can only learn, and grow, from making mistakes. No one is perfect. And the best thing about this build, you and I learn't a lot from it.
You understand the complexity of the build, and the fact that this supercharger build is almost completely custom, only shows that this was not as easy as slapping a charger in and calling it a day, as we soon discovered.
Let me clear this up for everyone on the forum, this kit needed a lot of fabrication. It was not a simple bolt on kit that you can buy from VF or AA or ESS etc. Yes, it was originally a VF engineering kit, but I wanted a Blow off Valve and Alpha N software, which VF do not do (also, VF's tuning is apparently left much to be desired and many VF members have since moved over to an evolve Alpha N tune). That mean't we needed to change the intake manifold, the MAF sensor needed to be replaced with a air temp sensor, which needed to be relocated into the intake manifold and upstream from the supercharger, as opposed to being before the supercharger. The recirculation valve needed to be blocked off from the supercharger intake, an idler pulley needed to be fabricated, the sump oil return line needed to be blocked off, new vacuum lines needed to run from the emissions rail to the blow off valve, a new idle control pipe needed to be fabricated, an oil catch can needed to be installed with a line running from the tappet cover to the oil catch can and the brake booster needed to be re-installed into the supercharger intake pipe. Also, the injectors used are 10mm taller than OEM. So a new injector rail bracket needed to be made as well as fuel line extender needed to be used. None of these fabrications are done by VF. Active Autowerke does most of these mods to their kit, so we picked some ideas from some of the guys running those kits, but I am pretty certain this is one of the first, if not the first, Active Autowerke / VF engineering Hybrid supercharger kit. The idea behind this build was to take the best of both kits and make it work. The super efficient and large V3 supercharger from the VF kit mixed with the design of Active Autowerke intake to work the Alpha N tune file provided by Project Shift.
None of the above mentioned things that were fabricated came with the kit. Burg did his best to make things work, and whilst most of these things were temporary, in the end, the build just needed Peter's attention to detail to give it that one last touch of perfection.
I take my hat off to Peter and Burg for meeting up and going over the fixes Peter made to the build. As much as Peter swore from under the car, I could see today that he was happy to show Burg the small details that were required to give it that lasting touch of awesomeness.
So... the car is supercharged. The fuel rail is secured and new injectors are in. Peter should have the intake pipes installed today, and tomorrow the car can go for AFR's and logging so a custom tune file can be made for her.
As I mentioned, this kit is completely custom, so I have no idea what will happen after we do AFR's. The charger has been sitting for 2 years now, I just hope the bearings inside are ok. The worst thing that could happen now is that the supercharger is kaput and we went through all of this for nothing.
LOL. ok, enough negativity. Till the next update...
Jezebel returns.
UpNcOmiNg!
Events Organiser
raise:This is awesome news.
The attention to detail will reward itself i'm sure!
Tareeq
Active member
This thread is so full of win I can't even begin to describe it. the attention to detail, the patience, the passion and so much more that has been put into this car is amazing raise:
I take my hat off to all those involved in this build it's really something amazing :bravo:raise: :thumbs:
raise:I take my hat off to all those involved in this build it's really something amazing :bravo:
raise: :thumbs:
I have connected everything and have let the car idle for roughly 1 hour.
All is well and I am satisfied that pieces will not fall off.
Car will be collected later to go to Project Shift for "mapping" and I am sure that Burgy will start his own thread with the mapping and software exercise.
I say this with the utmost sincerity " I do not wish to see Nita back here for a long time"
So please drive her with sympathy and due care.
Pics later tonight of the car finished
All is well and I am satisfied that pieces will not fall off.
Car will be collected later to go to Project Shift for "mapping" and I am sure that Burgy will start his own thread with the mapping and software exercise.
I say this with the utmost sincerity " I do not wish to see Nita back here for a long time"
So please drive her with sympathy and due care.
Pics later tonight of the car finished
I am optimistic that this pic of Nita will be the last one I take for a long time.
An interesting build for an owner who although always talks of his bad luck is most fortunate in so many ways.
In closing I never got to see the manicurist.........
An interesting build for an owner who although always talks of his bad luck is most fortunate in so many ways.
In closing I never got to see the manicurist.........
Crash_Nemesis
///Member
Ha ha ha... Peter you legend. Manucurist and two red heads will be provided to you plus a Venter trailer on my next movie set. You are the star of the movie so why not...
Thank you for all your help. Legend...
That being said, the drive home was relaxed, although I was stuck in Sandton traffic most of the way. It was a 25km trip from Peter's bat cave near William Nicol road to my Secret lab in Bedfordview (just off Gillooly's interchange near Eastgate shopping mall).
I had to sit in the traffic from Sandton all the way to the N3 and all the way on the N3 home. This is the consumption I got...
I also saw a similar drop in consumption with my supercharged 323i when driving relaxed. But when I put my foot down, it was the total opposite. More tests to come...
:thumbs:
Thank you for all your help. Legend...
That being said, the drive home was relaxed, although I was stuck in Sandton traffic most of the way. It was a 25km trip from Peter's bat cave near William Nicol road to my Secret lab in Bedfordview (just off Gillooly's interchange near Eastgate shopping mall).
I had to sit in the traffic from Sandton all the way to the N3 and all the way on the N3 home. This is the consumption I got...
I also saw a similar drop in consumption with my supercharged 323i when driving relaxed. But when I put my foot down, it was the total opposite. More tests to come...
:thumbs:
